Gain better understanding and insight into your plant data

Transcription

1 Gain better understanding and insight into your plant data Emerson Plantweb Insight Discover how you can make the most of plant sensor data with real-time actionable analysis of your operations.

2 Today s technology delivers more data than ever before - but are you getting the most out of all this data? Data is essential in making critical decisions for your operations and ensuring optimal operating conditions. When you are burdened with performing tedious manual rounds or unable to analyze your data quickly, essential information slips through your fingers. Without quick and accurate data analysis, it can be difficult to prioritize maintenance and identify potential hazards or failures, putting the safety, reliability and compliance of your facility at risk. Professionals in the automation industry say the main reasons they are collecting data are for process improvements (74.56 percent), diagnostics and predictive maintenance (67.58 percent) and quality control (51.37 percent).* Over 50 percent of businesses report that they have too much data to be able to analyze it efficiently though, and 44 percent report that they could do a better job at analyzing their data.** When you have access to instant, easy-to-read analysis of your key operational assets, you gain better understanding of your data. This knowledge allows you to make quick, critical decisions to increase operational efficiency, safety and compliance. * Are You Data-Driven? Industry Survey by AutomationDirect, CFE Media and Putman Media (participants were able to select multiple reasons) ** Strategy Analytics IoT 2016 Deployment and Trends Usage Survey 1 2

3 Plantweb Insight offers instant access and visibility to key assets, enabling you to make better, faster decisions for your operations. Plantweb Insight brings it all together by managing your facility data and providing data interpretation that enables you to make the critical decisions necessary to improve operational performance and safety. Engineered to work through plant sensors and networks, Plantweb Insight is able to provide real-time analysis of key asset data. This solution seamlessly integrates into your existing systems, offering automatic data interpretation. With Plantweb Insight, you can leverage data to reduce risk, save time and improve efficiency and safety. Gain better understanding of facility data with real-time analysis. Make manual rounds and inconsistent data communication a thing of the past. With Plantweb Insight, you have instant data interpretation of key asset health. Engineered with pre-built, industry-accepted analytics, this solution transforms sensor data into actionable insights. Safely access your data anywhere. The web-based platform allows you to securely access your data from anywhere at any time. Plus, the human centered design interface offers consistent and intuitive navigation across the apps. Shift strategy from reactive to predictive. With real-time visibility to key asset health, you can avoid potential safety hazards as well as better prioritize your maintenance. When you can spot abnormal situations before they become potential problems and prevent failures before they occur, you not only improve facility safety, but ensure your operations meet compliance and regulatory standards. Easily integrate pre-built analytics into your current systems. This solution seamlessly integrates with your existing wireless infrastructure, allowing you to expand the capabilities of your current system. Plantweb Insight can be used for any size operation. 3 4

4 Meet Challenges with Increased Process Insight Steam Trap Insight: Continuous steam trap monitoring Remove guess work Better prioritize maintenance with calculated insights from a steam trap status algorithm based on decades of process experience and analytics. Cut energy costs Real-time monitoring clearly displays economic and environmental impact in terms of excess energy costs and emissions loss. Steam Trap Failures Have a Major Business Impact Steam traps are typically only audited once a year, leaving plants vulnerable for long periods of time Expected steam trap failure rates range from 12.5% to 25% every year* 5-10% of total energy cost are typically lost through leaking steam traps** Avoid Costly Damage with Greater Visibility Continuous steam trap monitoring helps identify failures in real-time for quick repair and replacement Wireless provides a cost effective, reliable solution and non-intrusive transmitters make installation quick and easy Improve efficiency Rosemount 708 Wireless Acoustic Transmitter Quickly identify any steam traps that require attention: Blow through, plugged and flooded failure modes are immediately displayed. Ultrasonic acoustic level and temperature readings FM and CSA Class 1 Div 1 approvals Fast and easy to install and maintain Directly mount without cutting or changing pipe configuration No calibration Intrinsically safe power module with 10+ year battery life Steam Trap Insight determines the online health status of your steam traps by verifying if a trap is in failure mode. This is calculated using a status algorithm established by years of industry experience and analytics. The app utilizes data from the Rosemount 708 Wireless Acoustic Transmitters to continuously determine steam trap status. This includes identifying steam trap failures (blow through, flooded, plugged) and inactivity. For more information, visit Emerson.com/Rosemount-708 With this app, you can view trending of past health, emissions and energy loss on a per trap basis, and track impact set against key performance objectives. * Risko, J., Understanding Steam Traps, Chemical Engineering Progress, Feb 2011 ** U.S. Department of Energy 5 6

5 Impact of Pump Failures Comprehensive Monitoring for Enhanced Visibility Pump Insight: Gain clarity with pump health status and alerts Statistically, pumps will fail or suffer degraded operation every 12 months * Seal Monitoring conforms to API Standard 682 for pressure and level solutions Increase visibility Using a multi-measurement approach, continuous pump monitoring and analysis offers you greater visibility into your process and equipment conditions. Reduce costs Wireless capability easily integrates with your existing systems and provides a cost-effective approach for missing measurement points. Pump failures can cause process upsets and downtime, taking hours or days to recover to normal operations Reactive maintenance results in 50% higher costs than preventative maintenance ** Poor equipment reliability impacts HSSE in the form of safety incidents, regulatory fines and process shut downs Strainer Monitoring utilizes differential pressure across the strainer to identify plugging Cavitation Monitoring offers statistical analysis of process and vibration data to detect cavitation Vibration Monitoring provides early indication of vibration faults Be proactive Predictive diagnostics and analytic tools allow for preventive maintenance and prioritization. Multi-measurement Approach Emerson s wireless portfolio helps you establish all the necessary critical measurement points Pressure Level Pressure and DP Level Transmitters - Strainer Plugging - Discharge Pressure Variation - Seal Pressure - Suction Pressure Power Level Transmitters and Switches - Seal Level Pump Insight offers in-depth monitoring of fixed-speed pumps by providing an aggregated view into the health of all assets. Status and alerts are calculated by pre-built algorithms based on years of experience and industry-vetted analytics. The predictive diagnostics and alert weights of this solution enable better prioritization of pump maintenance, allowing users to mitigate recordable incidents and quickly identify any assets requiring attention. Vibration 56WM Wireless Power Meter - Voltage, Current, Power, Energy and other Electrical Parameters - Single and Three Phase Electrical Systems - Ensure Power Quality Hyrdrocarbon Leak Detection *ORED 09 5th Edition **NPRA Reliability and Maintenance Conference AMS 9420 Wireless Vibration Transmitter - Vibration and PeakVue (early indicator) - Bearing Temperature and Premature Wear - Cavitation Rosemount 702 Discrete Trasmitter with Liquid Hydrocarbon Detection - Hydrocarbon Leak Information - Leak Warning 7 8

6 Insufficient Monitoring Has Impact on Operations Heat Exchanger Insight: Increase efficiency with better understanding Complete Insight of Heat Exchanger Conditions Heat Exchanger Failures Have a Major Business Impact Avoid Costly Damage with Greater Visibility Unnoticed or increased heat exchanger fouling causes degraded performance and energy efficiency Reduce Production Loss Predictive and continuous heat exchanger monitoring helps optimize cleaning for enhanced production and energy efficiency. Cut Maintenance Costs Automated monitoring reduces costs caused by reactive maintenance. Proactively Monitor KPIs Continually calculate and track key performance indicators like fouling, heat duty and heat transfer coefficient. Fouling Monitoring provides early indication of fouling by comparing current heat transfer coefficient with baseline (newly cleaned) Reactive maintenance results in 50% higher costs than preventative maintenance* Heat Duty Monitoring quickly recognizes when heating requirements change Poor equipment reliability impacts HSSE in the form of safety incidents, regulatory fines and process shut downs Cleaning Recommendations are based on high fouling and high dp or lost energy costs Rosemount Measurement Solutions Get a complete picture of your processes by setting up a Pervasive Sensing network TM Rosemount 848T Wireless Temperature Transmitter - Monitors four independent temperature inputs - Configurable for RTD, thermocouple, ohm, millivolt and 4-20 ma inputs Rosemount X-well Technology - Non-intrusive point solution for process temperature - Uses pipe characteristic, ambient temperature and pipe surface temperatures to calculate process temperature Heat Exchanger Insight provides in-depth monitoring of shell and tube heat exchangers by analyzing plant sensor data gathered through existing infrastructure. Leveraging pre-built algorithms based on decades of process experience and industry-vetted analytics, this solution delivers reliable predictive diagnostics. Rosemount Wireless Differential Pressure Transmitter - Full portfolio of differential pressure transmitters - Monitors differential pressure across hot and cold sides Rosemount Wireless Differential Pressure Flow Transmitter - Best-in-class solution for accurate flow measurements - Cold and hot side flow used for fouling calculations *NPRA Reliability and Maintenance Conference 9 10

7 Common Threats to Air Cooled Heat Exchangers Air Cooled Heat Exchanger Insight: Make intelligent decisions about your ACHE Reduce Slowdowns Predictive and continuous air cooled heat exchanger monitoring helps reduce unexpected failures and process shutdowns. Exchanger Fouling Limited cooling is an indication of exchanger fouling. This can result in reducing the cooling capacity of the exchanger, leading to a throughput reduction. This can also cause products heading to storage tanks to be too hot or other process impacts. High Vibration and Bearing Temperature Increasing motor or fan vibration and bearing temperature can result in belt and coupling failure or can cause fan blades to stop, reducing the cooling capacity of the exchanger and throughput reduction. Other process, safety and environmental impacts can occur as well. Louver Mechanical Defects Faulty louver position can result in restricting airflow and cooling capacity reduction, leading to overall throughput reduction and other potential process impacts. Cut Maintenance Costs Automated monitoring reduces costs caused by reactive maintenance and manual rounds. Pre-built Models Save Valuable Time With access to pre-built strategic interpretation analytics, personnel no longer have to sort through large data sets. Install Wireless devices for better visibility across your facility Rosemount 848T Rosemount X-well Wireless Temperature Technology Transmitter - Monitors four independent temperature inputs - Configurable for RTD, thermocouple, ohm, millivolt and 4-20 ma inputs - Non-intrusive point solution for process temperature - Uses pipe characteristic, ambient temperature and pipe surface temperatures to calculate process temperature AMS 9420 Wireless Fisher 4320 Wireless Vibration Transmitter Position Monitor - Vibration and PeakVue (early indicator) - Bearing temperature and premature wear Air Cooled Heat Exchanger Insight provides in-depth monitoring of air cooled heat exchangers, fin fans, by analyzing wireless sensors data gathered through existing infrastructure. Monitoring Your Air Cooled Heat Exchanger Leveraging pre-built algorithms based on decades of process experience and industry-vetted analytics, this solution delivers reliable predictive diagnostics. - Equipment position with a percent of span plus on/off indication - Monitors louver position for mechanical defect detection Complete Insight of Air Cooled Heat Exchanger Conditions *NPRA Reliability and Maintenance Conference 11 Vibration Monitoring gives warnings of vibration and bearing faults, replacing manual rounds Heat Exchanger Fouling provides early indication of fouling using temperature readings Pitch/Louver Position Monitoring recognizes discrepancies in actual and expected position 12

8 Meet Challenges with Increased Process Insight Wireless Pressure Gauge Insight: Know before you go Enjoy more flexibility The Know Before You Go strategy enables users to remotely view pressure gauge readings and trends in order to stay updated on changing field conditions. Traditional gauges routinely fail, providing unreliable The Rosemount Wireless Pressure Gauge has a information without any indication. Basing robust design that resists common failures, delivers important maintenance decisions on these faulty dependable information about plant equipment and gauges can negatively impact plant safety and constantly informs users of its status. productivity. Engineered to Optimize Data Communication Improve workplace safety With remote monitoring, you reduce manual rounds and keep personnel out of hazardous areas, improving facility safety. Set to your specifications Industry-proven Rosemount pressure Innovative design provides overpressure protection WirelessHART technology delivers reliable field Local status indication allows personnel to have Manual configuration of thresholds for alerts ensures you get the data you are looking for. sensor technology replaces traditional mechanical components and dual layers of process isolation to keep personnel safe and ensure reliable data communications as frequently as once per minute. confidence in device health. and delivers up to 10 years pressure readings. of battery life. Engineered to Optimize Data Communication Wireless Pressure Gauge Insight monitors your wireless pressure gauges in a single, easy-to-use interface. This solution analyzes data acquired through plant sensors and existing infrastructure to provide real-time pressure status of all wireless pressure gauges. This application also features device health indicators, which help effectively manage maintenance. For more information, visit Emerson.com/ Rosemount-Wireless-Pressure-Gauge 13 14

9 Improve operations with strategic data analysis. Plantweb Insight is focused on monitoring the health of plant assets and provides the strategic data interpretation and analysis needed to prioritize maintenance and make informed decisions. Rosemount World Headquarters 6021 Innovation Blvd. Shakopee, MN 55379, USA or North America Regional Office 8200 Market Blvd. Chanhassen, MN 55317, USA or Latin America Regional Office 1300 Concord Terrace, Suite 400 Sunrise, FL 33323, USA Europe Regional Office Emerson Europe GmbH Neuhofstrasse 19a P.O. Box 1046 CH 6340 Baar Switzerland +41 (0) (0) Asia Pacific Regional Office 1 Pandan Crescent Singapore Enquiries@AP.Emerson.com Middle East and Africa Regional Office Emerson FZE P.O. Box 17033, Jebel Ali Free Zone - South 2 Dubai, United Arab Emirates RFQ.RMTMEA@Emerson.com Emerson.com/Rosemount Facebook.com/Rosemount LinkedIn.com/company/Emerson-Automation-Solutions Twitter.com/Rosemount_News YouTube.com/user/RosemountMeasurement Google.com/+RosemountMeasurement The Emerson logo is a trademark and service mark of Emerson Electric Co. Rosemount and the Rosemount logotype are registered trademarks of Rosemount Inc. All other marks are the property of their respective owners Emerson. All rights reserved , RevAA